Westerbeke 8.0KW-60Hz Service Manual

Single and three phase d-net diesel generators

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SERVICE MANUAL

8.0KW-60Hz . 6.0KW-50Hz EDT

10.0KW-60Hz· ·7.5KW-50Hz·EDT

. . 11.5KW-SOHz

9~2KW·50Hz

EDT

12.5KW-60Hz9.4KW-50Hz EDT

12.6KW-60Hz 10.4KW-50Hz EDT

15.0KW-60Hz 12.0KW-50Hz EDT

. - Single and Three Phase

:\D~NEt-D1ESEL-GENERATORS

PUBLICATION NO.54600

REVISIONl

JANUARY 2010

WESTERBEKE

WESTERBEKE CORPORATION • 150 JOHN HANCOCK ROAD

MYLES STANDISH INDUSTRIAL PARK· TAUNTON

02780

WEBSITE: www.WESTERBEKE.COM

....

..,.~~

NMMA Member National Marine Manufacturers Association

Table of Contents

Summary of Contents for Westerbeke 8.0KW-60Hz

Page 1 12.6KW-60Hz 10.4KW-50Hz EDT 15.0KW-60Hz 12.0KW-50Hz EDT . - Single and Three Phase :\D~NEt-D1ESEL-GENERATORS PUBLICATION NO.54600 REVISIONl JANUARY 2010 WESTERBEKE WESTERBEKE CORPORATION • 150 JOHN HANCOCK ROAD MYLES STANDISH INDUSTRIAL PARK· TAUNTON 02780 ..WEBSITE: www.WESTERBEKE.COM ..,.~~ NMMA Member National Marine Manufacturers Association...
Page 2 Shut down the unit and do not restart until it has been Inspected and repaired. A WARNING DECAL is provided by WESTERBEKE and should be fixed to bulkhead near your engine or generator. WESTERBEKE also recommends installing CARBON MONOXIDE DETECTORS in the living/sleeping quarters of your vessel.
Page 3 SAFETY INSTRUCTIONS INTRODUCTION PREVENT BURNS - FIRE Read this safety lfUmual carefully. Most accidents are caused by failure to follow fundamental rules and precau- WARNING: Fire can cause injury Of death! tions. Know when dangerous conditions exist and take the personne~ necessary precautions to protect yourself, your .
Page 4 Acid may splash on the skin or situation arises in which it is absolutely necessary to into the eyes inadvertently when removing electrolyte make operating adjustments, use extreme care to avoid caps. touching moving parts and hot exhaust system components . WESTERBEKE ...v' Engines & Generators...
Page 5 USCG and the NFPA. Sections of the ABYC standards of particular interest are: H-2 Ventilation P-l Exhaust Systems P-4 Inboard Engines E-9 DC Electtical Systems All installations must comply with the Federal Code of Regulations (FCR). WESTERBEKE Engines & Generators...
Page 6: Table Of Contents
Remote Oil Filter ..... : ......Valve Clearance ..........48 Remote Stop/Start PaneL ........ Air Intake .., ..........49 Hardware Chart ..........Testing Engine CompreSSion ......49 Metric Conversion Data ........Drive Belt Adjustment ........49 WESTERBEKE Engines & Generators...
Page 7: Installation
INSTALLATION When installing WESTERBEKE engines and generators it is important that strict attention be paid to the following information: CODES AND REGULATIONS Strict federal regulations, ABYC guidelines, and safety codes mnst be complied with when installing engines and generators in a marine environment.
Page 8 PARTS IDENTIFICATIO'N/GENERATORS CONTROL PANEL • LEFT SIDE CONNECTION TO BREAK -"or'nu .. COOLING AIR TO AIR INTAKE EXHAUST. TEMPERATURE r~t-t-:'--''-EXH,AUST ELBOW EXHAUST MANIFOLD ~~~-:-7"----STA,RTSOLENOID -STAIITER MOTOR REAR FRONT RAW WATER MANIFOLD PRESSURE CAP ~:-:--=--=--=- ..:.-~II':.F_IL_L ~~BLEED _-_-_-_-_-_-_- "" PETCDCK 'K\1Jk-'--~----", THERMOSTAT ASSEMBLY AIR INTAKE...
Page 9 I:ustomer lilentificationCard A,<I,di~lqnal.aetaue4 ihfun1l\ltionllliti'.pedfic~ti(jnsareptti~ .vldM.ijtQtli\lr·~ections of·tiii$jfu\ntiJ!!,·.roY~ijtj~the· \)!l&in' f .aqj us li!,~erl!!llt,.~1tt11'!l(ltot, st~rter·i1l()t()r, e nts, l!l1 \\QQti11lrl1!llllP$,e,I¢;...
Page 10: Engine Troubleshooting
ENGINE TROUBLESHOOTING NOTE: The engine's electrical system The following troubleshooting chart describes certain protected by a 20- problems relating to engine service, the probable causes of . ampere manual reset circuit breaker. preheat solenoid is these problems, and the recommendations overcome mounted on the same bracket.
Page 11 ENGINE TROUBLESHOOTING PROBLEM VERIFICATION/REMEDY PROBABLE CAUSE· LOW OUTPUT (cont.) OVERHEATING 1. Low coolant level. 1. Add coolant. 2. Loose V-belt. 2. Adjust or replace V-belt. 3. Adjust injection timing. 3. Incorrect injection timing. 4. Low engine all level. 6. Add engine oil. EXCESSIVE OIL OIL LEAKAGE CONSUMPTION...
Page 12 3. Replace. 3. Worn delivery valve. 4. Replace Injection nozzle. 4. Inadequate Injection nozzle spray. GOVERNING SYSTEM 1. Governor lever malfunctioning. 1. Check governor shaft and correct operation. 2. Replace. 2. Fatigued governor spring. (continued) ..,... WESTERBEKE EngInes & Generators...
Page 13 ENGINE TROUBLESHOOTING PROBLEM VERIFICATION/REMEDY PROBABLE CAUSE KNOCKING ENGINE KNOCKS WITHOUT MUCH SMOKE 1. Main engine troubles. See OVERHEATING; LOW OUTPUT. Overheated cylinder. b. Carbon deposits in cylinder. b. Clean. 2. Too early'lnjectlon timing. 2. Correct. 3. Too high Injection pressure. 3.
Page 14 #4 and #5. 6. Battery Voltage to ECU. 6. Check between pins P2-24 and P2-25. P2 ECU plug unplugged from ECU. Power turned ON. voltage Is present. ECU is faulty ..WESTERBEKE Engines & ,Generators...
Page 15: Testing For Overhaul
For additional information on alternators refer to the 5. Ant time the engine is assembled, new gaskets and ALTERNATOR TROUBLESHOOTING in this manual. a-rings must be installed. WESTERBEKE -.,.y: Engines & Generators...
Page 16: Engine.disassembly
ENGINE DISASSEMBLY GENERATOR ENGINE DISASSEMBLY Disconnect the AC wiring and unplug the engine's DC . Take the following precautions: wiring harness at the generator control panel. Remove the • Oean the exterior of the engine of deposits of battery cables from the engine and tape over the terminals. dirt and oil.
Page 17 ENGINE DISASSEMBLY Remove governor assembly. 23. Remove the cyfuider head assembly. the cylinder Lift head straight up with a hoist. a. Remove the tie rod cover. NOTE: if the gasket is seized b. Remove the spring from the tie rod with pliers to the cylinder hedd cannot disconnect the tie rod from t\1e fuel injection pomp.
Page 18 ENGINE DISASSEMBLY 27. Remove the rear plate.The rear plate is doweled in VALVE SPRING ' position. Pull the plate as straight as possible when REMOVAL removing it. 28. Remove the oil seal case. Remove the bolts that hold the oil seal case in position. Remove the case from the linder blC)ck with a screwdriver.
Page 19 ENGINE DISASSEMBLY TIMING GEARS ORDER OF DISASSEMBLY NUMBERS INDICATE THE , . SUGGESTED ORDER OF INJECTION PUMP CAM~I:IAFT DISASSEMBLY. . IDLER GEAlf . REMOVE 9 THRU 11 AS AN ASSEMBLY 1.;J~r.'nINu. ·12 FUEL iNJECTION" . 'PUMP CAMSHAFT 'REMOVE THRU 14 AS AN ASSEMBLY .
Page 20 ENGINE DISASSEMBLY 31. Remove the timing gear case. Remove the bolts that 37. Remove the oil pump. Remove the bolts that hold the oil hold the timing gear case in position and remove the case. pump the cylinder block and remove the pump. 38.
Page 21 ENGINE DISASSEMBLY 41. Thrust clearance measQrement for connecting rod big 46. Remove the crankshaft. end. Install the connecting rod to its crankpin and tighten the cap nuts to the specified torque. Measure the thrust CAUTION: Do not cause damage to the' clearance with a feeler<...
Page 22: Engine Inspection
ENGINE INSPECTION he~vy head. Cylinilei:' Usil1g a accurate straight edge and CYLINDER HEAD'AND VALVE MECHANISM a feeler gauge, check the bottoril face for warpage in three positions; lengthwise, two crosswise and two widthwise as CHECK shown in the ilfustration. warpage exceeds the limit, THREADS refaee.
Page 23 CLEARANCE BETWEEN THE VALVE STEM AND VALVE GUiDE INLET VALVE: STANDARD 0.008 - 0.0020 (0.02 - 0.05mm) INSPECTING THE LIMIT 0.0039 in (0.10mm) BEND THE PUSH EXHAUST VALVE: STANDARD 0.0020 - 0.00336 In (0.05 - 0.085mm) LIMIT 0.0059 in (0.15mm) ''''''WESTERBEKE Engines & Generators...
Page 24 ENGINE INSPECTION ' 0.39±,0.02o In (io±0.5 mm) GUIDE~t7r..."._-,·_..;t,-' VALVE _" _" CYLINDER HEAD ' GOOD CONTACT MUST BE UNIFORM '" AROUND THE COMPLETE CIRCUMFERENCE HEIGHT TO THE TOP OF THE VALVE NORMAL SIZE 0.39 in (lOmm) VALVE AND VALVE SEAT CONTACT c.
Page 25 ENGINE INSPECTION I-L. __ '\UU'\U L _ _ COMI~USTIIONJET c. After refacing the valve seat, put lapping c.ompound on 9. Combustion jet replacement. Replace the combustion the valve face and lap the valve in the valve seat. jets only when they are cracked or defective. 8.
Page 26 ENGINE INSPECTION TIMING GEARS AND FLYWHEEL· INSPECTION POINTS TAPPET INSPECT FOR ,,~n GASKET CAI\lSHAFT BEARING CHECK FOR NOlllE (S'PINAIING) AND WEAR. GEARS CHECK TEETH WEAR. BURRS. OR CHIPS CHECK FOR BEND OR DAMAGE TO THE LOBES r-----:-----"TINII.A GEAR CASE iii",;",.., <(io CRACKS/DISTORTION GASKET'...
Page 27 ENGINE INSPECTION 10. Camshaft Measure the lobe height and base circle as shown in the illustration. Subtract the baSe circle' from the a. Measure the diameter of the joUrnal and the bore in the lobe'height to find the lobelift. If the lobe lift bushing for the shaft to find the clearance as shown in exceeds' the limit, replace the camshaft.
Page 28 ENGINE INSPECTION Idler gear. 15. Pistons; piston rings and piston pins. a. Measure the bore in the idler gear for the shaft and the a. Measure the diameter of the piston at its skirt in a direciion transverse to the piston pin with a micrometer diameter of the shaft find the clearance.
Page 29 TEETH FOR DAMAGE. MAIN BEARINGS /NSPECTFOR ." LOSS OF OVERLAY MAIN BEARINGS' INSPECT FOR SCRATCHES INSPECT FOR DETERIORATION LOSS OF OVERLAY. INSPECT FOR SCRATCHES AND OIL. TUBE WITH KEROSENE. INSPECT FOR DETERIORATION AND RUST. REPAINT IF NECESSARY. WESTERBEKE Engines Generators &...
Page 30 ENGINE INSPECTION f. Check the connecting -rod for bend or twist as follows: d. Pul'the piston ring In a gauge or in the bore in a new "k'. cylirider plock and measure the clearance between the (1) Measure "C" and "C"...
Page 31 0.25mm {0.0098 In) FINiSH.. 47.75·'·' mm (1.8799 •. "'"' in) . MEASURING THE 0.50mm {0.0197 In) DIAMETER OF FINISH 47 .50 mm (1.8701 . ..,,,. in) THE JOURNAL 0.75mm (D.0295 In) FINISH 47.25·'·' mm (1.8602 .,.,." In) WESTERBEKE Engines & Generators...
Page 32 ENGINE INSPECTION (3) If the clearance exceeds the limit, install a new 17. tyUnderBlock bearing and check the clearance again. a. Measure the bore at the top, middle and bottom points (4) If the clearance still exceeds the limit, grind the " .
Page 33 ASSEMBLY CYLINDER BLOCK, CRANKSHAFT; PISTONS AND OIL PAN PISTON COAT THE ENTIRE SURFACE WITH ENGINE OIL 'PISTONPIN~ FORCE FIT CAMSHAFT APPLY ENGINE OIL TO JOURNALS AND LOBES BEARINGS Z~ ~ LUBRICATETHE INSIDE SURFACES WITH ENGINE OIL BEARINGS ~ ~. LUBRICATE THE INSIDE SURFACES WITH ENGINE OIL CONNECTING ROD - - - - - - - - .
Page 34: Assembly
ASSEMBLY 1. Main bearing installation. 4. Side sesi installation. a. Install the upper halves of the main bearings in the a. Coat !he side seals with Loctite Ultra Blue. cylinder block ano the lower halves in the main Insert the side seals between the cylinder block and the bearing caps so their tabs fit into the notches in the front and rear caps and push them in by hand as far as cylinder block and the main bearing caps ..
Page 35 ASSEMBLY 8. Connectfug rod installation. MARK TO a. Push the piston into position until the big end of the connecting rod is put into position over the crankpin. • Then the crankshaft 180 while pushing on the top turn NO.1 COMPRESSION of the piston.
Page 36 ASSEMBLY TIMING GEARS ANIl'FLYWHEEL TAPPETS LUBRICATE VVl/11'--_ ENGINE OIL THRUST PLATE TORQUE TO: . 0.1 Kg-m ± 10.8 1 Nm ± APPLY ENGINE OIL TO JOURNALS AND LOBES GASKET GASKET BACK PLATE BOLT TORQUE TO: 17.5 2.5 Kg-m ± 1 Kg-m ±...
Page 37 ASSEMBLY 11. Front plate installation, a. Scrape the gasket from the cylinder block and front plate. b. Coat the gasket contact surface of the cylinder block with adhesive and put a new gasket in position, making sure the holes in the gasket are all in alignment with the holes in the cylinder block.
Page 38 ASSEMBLY b~ttom CyliDder head face cleanmg. Scrape the gasket 23. Flywheel installation. fr011lthe bottom face of the cylinder head. a. Install a safety bar (M12x 1.25) in the rear end of the NOTE: After scraping the gasket, rub off gasket remnants crankshaft.
Page 39 ASSEMBLY 29. Installation of the cylinder head. Place the cylinder 37_ Fnel injection nozzle instaIIation. head in position on cylinder block, making sure the Put the gasket on the nozzle. guide bolts are all in aligmnent with their respective bolt b.
Page 40: Actuator
Put the belt in position on the pulley, Move the alternator away from the engine to make an adjustment to the belt. c. Tighten the bolts. d. Make sure the tension of the belt is correct, about 2"deflection at the center with pressure. WESTERBEKE . Engines Generators &...
Page 41: Heat Exchanger
They will coolant recovery tank tubing. also service transmission and engine oil coolers. Flush out the coolant recovery tank and it's connecting 6. Repaint the assembled heat exchanger with Westerbeke tube. h!'!~t r<"isltant spray enamel. ASSEMBLY 1.
Page 42 Keep the disassembled injeciion pump parts in clean diesel fuel. CAUTION: Anytime the injection pump is disassembled, new O·ring must be installed. Make sure the threads the delivery valve holder do not cause damage to the O·rings. WESTERBEKE Engines & Generators...
Page 43 FUEL INJECTION PUMP 6. Inspection after assembly. 3. Install each control sleeve with the center tooth in alignment with the line mark of the control rack. Put a. After the injection pump has been assembled, check to the plungers in position in the .barrels. see it'the control rack moves freely without any .
Page 44: Governor
GOVERNOR DISASSEMBLY SEQUENCE AND INSPECTION ·~---2 TIE ROD SPRING ~_---+ CHECK SLIDING SLEEVE CONTACT ;FACE FOR WEAR k----3 SPEED CONTROL LeVER ·GOVERNOR CASE SHAFT/ CHECK SHAFT FOR DEFECTS AND WEAR 1. Assembly. SPEED CONTROL a. Install the levers in position. b.
Page 45 IT mark with respect 'to the mark on the gear case. timing is This ADVANCED . approximately 1° retarded Take 1° retardation this ihto accouitt.when making a shim adjustment. ..-v: WESTERBEKE Engines & Generators...
Page 46: Fuel Injectors
NOTE: The copper washers sliould not be reused. 'Replace with washers. 2. TIghten the nozzle on the cylinder head to the specified torque. NOZZLE TORQUE 40 ± 4lb-ft (5.5 ± 0.5 kgl·m) ..Y.._ RECONDITION (REPLACE WESTERBEKE -.¥ Engines Generators &...
Page 47: Glow Plug Testlng
GLOW PLUG TESTING GLOW PLUGS TERMINAL inspect the plug, remove the electrical tenninal connections, END· then unscrew or unclamp each plug from the cylinder head. Thoroughly clean each ping's tip and threads with a soft brush and cleaning solution to remove all the carbon and oil deposits. While cleaning, examine the tip for wear and burn erosion;...
Page 48 STARTER MOTOR· No-Load Test DESCRIPTION 1. Connect the anuneter, voltmeter, and battery to the starter The starter can be roughly divided into the following sections: as illustrated. • A motor section which generates a drive power. • An overrunning clutch section which transmits an arma- 2.
Page 49: Starter Motor
STARTER MOTOR Return test: With a. battery connected to the solenoid ter- minal M (-) and the starter body,. nianually pull out the ~ COI.MICITOA Off pinion fully. 'The pinion must return to its original position ..-':~~~ when released from holding hand.
Page 50 STARTER MOTOR STARTER INSPECTION ,CI •• eIJSeLOTH Solenoid Inspect the solenoid for continuity between terminals S and M 'l'ld-between terminals S and body. No continuity should qe found between S and M: Continuity should be found ' between S and the body and M and the 'body. Insl~ec Brush and Brush Holder 1.
Page 51 STARTER MOTOR' COMMUTATOR MICA UNDERCUT STARTER ADJUSTMENT AND REASSEMBLY Measure the undercut of micaiusulation between the adja- Bef~/e cent segments. If undercut exceeds the limit, recondition the CAUTION: Insta/llng, tholoughly clean the mica or replace the annature. starter Bange and mounting surtaces, lemove all oil, old mm) .
Page 52 48Q~q) BIlWWATEBRUMR fRN. " 2. . Install the oil seal'in the pump housing. Disassembly 3 •. Support the pump.Lubricate the shaft and slide it thru the NOTE: Refer to the following poge for parts list and exploded oil :sem and press the bearings with shaft into the housing vievv.
Page 53 ,---" ./'""' KEY NO. PART NUMBER AND'PART NAME QUANITY 48080 RAW WATER PUMP 49172 SHAFT NOTE' 49170 IMPELLER COVER THE PUMP·REPAIR KIT (49000) 48500 IMPELLER KIT (D-RING & GLYCERIN) , INCLUDES THE USTED 34458 COMPONENTS JI)(CEPT ITEMS 1 AND 7..THE KlT ALSO INCLUDES 49171 WEAR PLATE A PUMP MOUNTING GASKET.
Page 54: Engines
(TDC) IT MARK stroke. Each cylinder is adjusted following the engine's firing ON PULLEY order (1-3-2 for WESTERBEKE three cylinder engines). Valve adjustment beginning with cylinder #1. Rotate the craokshaft slowly and observe the operation of the valves for cylinder...
Page 55 181166 AQ.JDIIMENtS Alwitlr4({E~Lg.Q,~~Gat tESl'ING·ENGINE:U6\'v1PRESStOtl ..·etafffi'e. a.Wamt:tlie'~iill,!ojiioj!/jlIDiJeerati b,~m"J:il!l~·~il!t.Q);l~.)!!\!; . " '\)t!i~~' ff\~J; ·~I1j~Jl!'i.)l~~l]:.l,tIl!llW~$.i :$l' 1 111l\Oit( lsq~e~n;...
Page 56: Oil Pressure
ENGINE ADJUSTMENTS OIL PRESSURE The engine's oil pressure, during operation, is indicated by the oil pressure gauge on the instrument panel. During normal operation, the oil pressure will range between 40 and 60 psi (2.8 and 4.2 kg/cm'). ~~~SSUllE, . OIL NOTE: A newly started, cold engine can have an oil pressure SENDDR reading up to 60 psi (4.2 kg!clrf).
Page 57: Actuator
ENGINE ADJUSTMENTS PICK~UP . MAGNETIC [MPU] INSTALLATION ACTUATOR (ELECTRONIC GOVERNING) The BCU (Electronic Control Unit) in the control box on the The MPU is installed in the threaded opening on the side generator controls the engine speed electronically. The BCU of the flywheel bellhousing.
Page 58 SERVICE DATA· STANDARDS AND LIMITS Component Standard Repair Umlt Standard 'Component Repatr Limit inm (inches) mm (inches) mm (inches) mm (Inches) ENGINE COMPONENTS ENGINE COMPONENTS Compression pressure ....427 psi at 280 rpm ....••..• 384 psi Lobe height of fuel injection .
Page 59 SERVICE DATA· STANDARDS AND LIMITS Component Specified Value Standard Repair Limit Sealant Component Mating Part inches(mm) inches(mm) THREAD PARTS ENGINE COMPONENTS Stop solenoid ..•..•...loctite #587 Ultra Blue ..••••• Governor case Crankshaft Water drain jOint....Loctite Gasket Sealer #2 ..Cylinder block Diameter of journal ....
Page 60: Alternator Testing
WARNING: A working alternator hot. A failed The following infonnation applies to the stal)dard alternators alternator can become very hot. Do not touch the that are supplied with WESTERBEKE'S Engines and Generators. alternator until has cooled. ELECTRICAL CHARGING CIRCUIT LOW BATTERY/FAULTY CIRCUIT...
Page 61 5. Check the battery voltage. If your battery is in good condition the reading should be 12 to 13 volts. TESTING THE OUTPUT CIRCUIT ENGINE RUNNING i100RANGEB TO STAH:rEllliOLE~liIlD ~£ 1It6V10LET R ... WESTERBEKE TO K'3RELAY Englneil & Generators...
Page 62 If tests indicate a failed alternator, it will need to be disas- sembled and repaired. Any good alternator service shop can do the job. NOTE: WESTERBEKE'S Service MaJluallws detailed instructions for the disassembly and repair of their" standard altemlltors. BATTERY CARE The minimum recommended capacity of the battery used in 3.
Page 63 ~ \~ . ~!'~ ' = U...
Page 64 WIRING. DIAGRAM #54655 u. _ .. -" _ .. -" -" -" - .: -" (10 -15KW EDT THREE PHASE 24V), JJ[T DATTfRY 24 YDC SWiTCH ,~--~---------, m~~~R f~h~~:~I~i~~~oRsf !!!~ - REFEII TO OPERATOR MANUAL 'I~lRG FOR OTHER At -, IITP 111M 'NllE : 'rcu...
Page 65 ,,/"--' WlllIfIl(i DlA(iRAIV! .#53477 (5.5KW EDC!7.6-15 EDT 24V)· BAnEIIY R£fEIIPIMSmft [11CII11 DIWEI ~IIGR1II 24 VGC SW ITCH FQiI)(: ca.~tCTloM. ---, d~::~---IZ£lc------ &~ -::;:,=- , ., 111M 112m/11lI CAlLE ------- IW:a::;; 1111 r·L..tt=' _1DI'.~ I "I~i g:tl 0 0 0 o· .I(j II! '1M s·...
Page 66 I I I , " '" " , .~----:f-- I~I~ II~!' : rEI! l.':====-.!J-.! _ _ _ _ "'~--r-I. ,., \ m l l l " _ -UII!AlIII - - - - - -' - - - ~WESTERBEKE..., Engines & Generators...
Page 67 ~> " t=<O-J' " [~-;-~~ ~l " 011110 '<;: 1m:)) ~,0D P,~' " ~~,~ i~!' . . . " . , : jf'!1 """ " : "" ' " I- r' , "JL--'" ; '~rll .:..;;: I ::: g...: ''-'..=l""i !&.:L ~<-;h 1 - .
Page 68 "~ BlIItII .=./ mill ~~,g'lJ (~m'll ~/~IDOII UII ~II QUlI.x r+--..".-",,,.r" 0)1111 A!h' . lii~' " ;-L~; ,~==$; ==~~):I~,-=L 1 _ _ _ 1 _ _ _ "'''.~, mil' ---I ; I - WES7CFlBEKE Engines & Generators ~'" ~~p:(}-~ ,mm.,,'...
Page 69: Raw Water Pump
Valve Seat Angle Intake 45' 011 Grade API Specmcation CF or CG-4, Exhaust 30' SAE 30, 10W-30, 15W-40 Valve Clearance 0.25 Inches (0.0098 mm) 1991 0 psi (140 5 - 0 kg/fcm'). Injector Pressure Engine llming 17' BTDC WESTERBEKE Engines & Generators...
Page 70 SPECIFICATIONS· GENERATOR 11.5/9.2KW EDT AC GENERATOR (Single Phase) AC GENERATOR (3 Phase) flel~. BllIshless, four pole, revolving General- 3 P)1ase BllIshless, siX-pole, revoMng !leI\!. 8eal00 Single Phase 'Pre-lubricated, single bearing design. 11.5 Kw ·80 Hertz lubricated, single-bearing design. 12 Lead Reconnectable, single phase tmnsformer 9.2 Kw·...
Page 71 (60 Hertz) at 1800 rpm NOTE: Increase air supply 15% for 50 Herlz opemUon (1500 rpm). operation (1500 rpm). 12fF maximum (Sot) Generator Compartment Generator Comparbnent 12fF maximum (Sot) Ambient Temperature Ambient Temperature Recommendations Recommendations '"' WESTERBEKE Engines & Generators...
Page 72 SPECIFICATIONS· ENGINE EDT.12~6!10.4KW 8.0/6.0 KW EDT, 10.0n.5 KW EDT, 11.5/9.2 KW GENERAL FUEL SYSTEM Engine Type OIesel, four-cycle, three-cylinder, fresh water- General Open flow, self priming;' coo~d, vertical in-lna,overhead valve Fuel No.2 diesel ali (eotane rating 45 or higher). mechanism. Fuel InJection Pump In-line plunger type (BOSCH).
Page 73 o.on SPECIFICATIONS· GENERATOR 1 .5KW EDT AC GENERATOR (3 Phase) AC GENERATOR (Single Phase) Three PhaSe Brushless, six-pole, revolving field. Sealed Single Phase Brushless, four-pole, revolving field. 10,0 KW-60 Hz . lublicated, single-bearing design. 12 Lead Pre-lubricated, single-bearing daslgn. 7,S KW - 50 Hz reeonneclable for low voHage WYE, high Reeonneclable, single-phase transformer regulation (optional solid-state voltage...
Page 74: Generator Information
120 volt AC hot leg for the distribution are entering your boat. panel. This will ensure good motor starting response from the . carbon monoxide is present, ventilate the area with generator: clean air and correct the problem immediately! ..WESTERBEKE Engines Generators &...
Page 75 'r __ " -:-;;-;0 REEN GREEN AC 9 F)'-- - ... , GREEN GREEN YEllOW! YELLOW ,-;;,-;;;;;;-,--,I\:--:;;,--,!, BLACK B~CK "-~~~~~====~B~LA~tK~====~~~~~l===~B~~~C~K======~~~~ BLUE 60cyc. -IAN.R.I-_ _ _ _ --v;;;;--rnrr-_ _ _ _ BLUE 50 eye. YEllOW PLUG WESTERBEKE -.¥ Engines & Generators...
Page 76 BT GENERATOR TROUBLESHOOTING/SINGLE PHASE 3. Transformer Auxiliary Windings. Resistance is Main Stator Windings measured between the yellow wire lifted off the AC ter- 1. Group #1. The resistance value is measured between the minal block of the bridge rectifier (0) with the selector lifted lead the insulated teni:linal below the trans·...
Page 77 _________________ J RED/WHITE (l'O HI!RTlNOLTS eAR) PLUG BLUE/WHII'E BLACK/WHITE (fO PIN 18TERM. (TO SELECTOR SWITCH) BLUE/WHITE YELLOW IWHITE HEFI17NOLTS BAR) (l'O SELECTOR SWITCH) BLACK/WHITE (TO BRIDGE RECTIFIER) BT GENERATOR INTERNAL WIRING SCHEMATIC (W/OPTIONAL AVR) .. ~fErro.r----------~~~j_~;;;:;;~~~;;= ·50c~ WESTERBEKE Engines & Generators...
Page 78 DT GENERATOR SINGLE PHASE 12 STUD D COMPOUND TRANSFORMER WINDlNGL.019-.021Q COMPOUND TRANSFORMER' AUXILIARY WINDlNGS _ _ _ _ _ COMPOUND G BRIDGE RECTIFIER TRANSFORMER ACTERMINAL BOARD BRIDGE BREAKER RECTIFIER JUNI:TlON TERMINAL 1 & 4 , . WESTERBEKE " , Engines & Generators...
Page 79 , TESTING THE showing a passage of meter voltage through the diodes in BRIDGE RECTIFIER the rectifier. NOTE: Currimt BT Generators'use a bridge rectijier that is r.' =~I conjigured differently, connectiQns are the same. WESTERBEKE Engines Generators &...
Page 80 AC output voltage to drop to zero. battery. A short or an open in a diode can easily be found with the above without having to unsolder and isolate each diode to' check it with an ohmmeter. WESTERBEKE Engines & Generators...
Page 81: Generator Frequencynoltage Changes
VOLTAGE/IIERTZ CONNECTION BAR ' CURRENT MODELS (REPOSITiON THIS WiRE EARLY MODELS FOR 50Hz) 'YELLOWIWHITE , RED/wHITE ' '" " RED/WHITE BLUE ... WESTERBEKE Engines & Generators...
Page 82 GENERATOR FREQUENCYNOLTAGE CHANGES F~EQUE~CY GENERATOR CHANGES (HERTZ) c. Note: On six stud AC models oruy when an optional AVR is installed, reposition the blue/white lead to 1. Frequency is a direct result of engine/generator speed. correspond to the hertz selected on the voltage/hertz 1800 rpm 60 Hertz connection bar.
Page 83 NMEA·2000 system or shut off the DC breaker on the gener~tor:S control boxfor a,WESTERLlNK system. BliMP . 20 AMP DC CIRCUIT NOTE: Keep in mind that the Westerbeke generator maybe pANEL~ PROTECTS" . BREAKER (ECU) power supply for the vessel NMEA-2000 ne/Work.
Page 84: Voltage Regulator Adjustments
BT GENERATOR INTERNAL WIRING 3 PHASE TWELVE WIRE RECONNECT ABLE r- - - - - - - : - - - - - - , EXCITER STATOR r------, DSTATOR -I- - - - - - - - - - - - - - I 10' ·9...
Page 85 BT GENERATOR TROUBLESHOOTING/3 PHASE NOTE: AC GENERATOR TROUBLESHOOTING MUST BE PERFORMED WITH THE ENGINE OPERATING AT 60 HZ FAULT PROBABLE CAUSE NO AC VOLTAGE OUTPUT AT NO LOAD. Short or open In the 4. Open In exciter main stator winding. stator winding.
Page 86 BT GENERATOR SINGLEJTHREE PHASE This generator is a four-pole, brushless, self-excited generator A circuit breaker is installed on all WESTERBEKE genera- tors. This circuit bre\lker will automatically disconnect gener- which requires' only the driving force of the engine to pro- ator power in case of an electrical overload.
Page 87 3. Increase the engine speed to its norma! speed (frequency). The red "LED" light will go out and the AC voltage out- Stab Vol! put will return to normal. With the above adjustments made, the regulator should func- tion ilomtally. VOLTAGE REGULATOR DIAGRAM WESTERBEKE Engln/'$ Generator$ &...
Page 88 Degree Celsius ('C) = ('F - 32) x .56 LIQUID WEIGHTS Diesel 011 = 1 US gallon ~ 7.131bs Fresh Water = 1 US galion = 8.331bs Gasoline = 1 US gallon = 6.1 Ibs Salt Water = 1 US gallon = 8.56 Ibs WESTERBEKE ~~gl~~s:!,-.G~nerators...
Page 89: Special Tools
CAMSHAFT BUSHING INSTALLER [0335831 FOR REMOVING AND INSTALLING THE FRONT CAMSHAFT BUSHING 033583 THE ABOVE TOOLS ARE AVAILABLE FROM YOUR WESTERBEKE OR MITSUBISHI DEALER. NOTE: IN AODITION TO THESE TOOLS THE FOLLOWING ADDITIONAL TOOLS WOULD BE NEEDED: BEARING PULLER, VALVE SEAT CUTTER TOOL, PROPER DIAL GAUGES, VALVE GUIDE INSTALLER TOOL, VALVE SPRING COMPRESSOR, SNAP RING PLIERS, ETC.
Page 90: Remote Oil Filter
REMOTE OIL FILTER (OPTIONAL) INSTALLATION NOTE: Westerbehe is not responsihlefor engiM failure due to incorrect installation the Remote Oil Filter. . frhls popular accessory is to relocate engine's oil fil- used ter from the engine a more convenient location such as an ~ngine room bulkhead.
Page 91 STANDARD HARDWARE BOLT HEAD MARKINGS Bolt strength classes are embossed on the head of each bolt. Metric boll class numbers identify bolts by their strength with 1 0.9 the strongest. Customary (inch) bolts are Identifed'by markings two to grade eight (strongest).
Page 92 METRIC CONVERSIONS LENGTH·DISTANCE Inches (in) x 25.4 " Millimeters (mm) x .0394 = Inches Feet (ft) x .305 = Meiers (m) x 3.281 = Feet . Miles x 1.609 = Kilometers (km) x .0621 = Miles. . DISTANCE EQUIVALENTS 111.~20 1 Degree of Latitude"...
Page 93 0.90625 27/64 0.421875 10.71562 0.921875 23.41562 59/64 7/16 0.4375 11.11250 0.9375 23.81250 15116 0.453125 24.20937 29/64 11.50937 61/64 ' 0.953125 15/32 0.46875 0.96875 24.60625 11.90625 31/32 31/64 0.484375 12.30312 0.984375 25.00312 63/64 0.500 12.70000 1~00 25.40000 WESTERBEKE Engines & Generators...
Page 94: Specification Charts
INDEX Actuator ......34 , 51 Measuring Piston ......22 Metric Conversion Data ....86, 87 Air Intake Filter ......49 Alternator Testing ......54 Oil Pan ......... 29 Oil Pressure ......50 Assembly ....... 28 Oil Pump ........
Page 95 Engines & Generators 1146WM/DW1/2D1 D"...

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Westerbeke 8.0KW-60Hz Service Manual

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